Universal tv bulb packaging insert



July 11, 1967 R GRAVE-5 ET AL 3,330,407

UNIVERSAL TV BULB PACKAGING INSERT 2 Sheets-Sheet 1 Filed Aug. 14, 1964 Fa Pu INVENTORS. Randall W. Graves Lewis E Reas A T TOR/YE Y y 6 R. w. GRAVES ET AL 3,330,407

UNIVERSAL TV BULB PACKAGING INSERT Filed Aug. 14, 1964 2 Sheets-Sheet 2 INVENTORS. Randall W Graves Lew/s E Rees MW/32M,

A 7. TOR/V5. Y

United States Patent 3,330,407 UNIVERSAL TV BULB PACKAGING INSERT Randall W. Graves, Elmira, and Lewis F. Reas, Big Flats, N.Y., assignors to Corning Glass Works, Corning, N.Y., a corp oration of New York Filed Aug. 14, 1964, Ser. No. 389,761 13 Claims. (Cl. 206-65) This invention relates to a contoured foam plastic insert for packaging television tubes, and more particularly to a molded expandable polystyrene foam packaging element for use in multipacks of specialized television tubes.

In order to control implosion, and as a safety factor, television tube manufacturers have incorporated metal perimeter-tensioning bands about the tubes. These specialized tube types have metal tube-mounting lugs attached to the four corners of the perimeter bands. Various perimeter band systems are now in use in the TV industry and these vary in design and dimension detail, although the performance objectives are the same.

The first such system is called the Rimband system, and utilizes a split ring held by a constant-section steel band which may be secured by a locking clip or spot weld. The Rimbaud type of tube may be provided with various forms of mounting lugs. The standard Rimbaud tube is provided with mounting lugs at each corner which extend radially-outwardly from the band itself, so as to lie substantially within the plane of the band. The ofiset Rimband tube is provided with mounting lugs at each corner which are offset longitudinally of the tube, and have an outwardly-extending mounting portion displaced from the plane of the band. The second system is called Shelbond, and utilizes a stamped sheet metal mask, plastic-bonded to the glass with a peripheral flange, and having perforated corner portions forming the mounting lug surfaces.

It has been extremely difiicult in the past to protect and confine the metal mounting lugs which protrude from the face corners of such tubes during shipment, such as in palletized bulk packs. The lugs not only tended to cut through the partitions placed thereabout for protection, but also through the outer corrugated paperboard carton. Further, the lugs had a tendency to bend upon each other, which, of course, impaired the mounting alignment in the finished TV set.

In an attempt to alleviate these problems, numerous corrugated inner-packing elements were proposed and tried, with the result that the existing multi-pack design style became extremely complex to fabricate and assemble. Mthough numerous multiply-folded corrugated inserts were required to position such specialized tubes Within bulk packs, thus adding to the cost and time required for packaging, the resulting protection produced by such inserts has not been completely satisfactory for the above reasons. Other materials and approaches were also explored but all were extremely costly and complicated to assemble.

The present invention alleviates the problems heretofore encountered in packaging specialized television tubes by providing a molded foam part contoured to complementarily receive any of the various specialized tubes and cushionably position such tubes in snug orientation within a bulk pack.

It thus has been an object of our invention to provide a universal packaging insert adapted to snugly package any of the known specialized TV tubes in cushioned relationship within an enclosing container.

A further object of our invention has been to provide a universal packaging insert for specialized TV tubes of a given size which accommodates and protects the mounting lugs projecting outwardly from the corners of such tubes during shipping and storage.

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An additional object of our invention has been to provide an improved packaging insert having high energyabsorption characteristics contoured to conform to the bounding edge surface of avariety of specialized tubes so as to distribute any impact loading along a relatively large surface area.

These and other objects of our invention will become more apparent to those skilled in the art from the following description and accompanying drawings forming a part of the specification, wherein:

FIGURE 1 is a plan view of a packaging insert embodying our invention;

FIGURE 2 is a front elevational view of the insert shown in FIGURE 1;

FIGURE 3 is an elevational view in section taken along line III-III of FIGURE 2;

FIGURE 4 is an elevational view in section taken along line IVIV of FIGURE 2; and,

FIGURE 5 is a somewhat schematic fragmental plan view of a multiple pack illustrating the various types of specialized tubes which may be packaged by our universal insert, and their relative positionment with respect thereto.

Referring now to the drawings, the foam insert or packaging part embodying our invention is in the form of a fiat, slender rectangular block or body member 10 having a contoured front face 11 relieved to complement the side contours of a variety of specialized TV tubes of desired size. Due to packaging characteristics, it is preferable to contour the surface 11 to complement the minor axis contours of larger TV tubes, such as the 23" tubes; whereas, with the smaller TV tubes it may be preferable to contour the surface 11 to cooperate with the major axis contours. The contoured front surface 11 extends vertically between a pair of planar support surfaces 12 and 13. In addition, the body member 10 is provided with a pair of end surfaces or side walls 14 and 15, and a back wall or surface 16.

The contoured surface 11 is provided with an inner recessed portion 17 communicating with planar surface 12. A contoured step portion 18 communicates between inner recessed portion 17 and an intermediate recessed portion 19. An outer recessed portion 21, communicating with planar surface 13, is outwardly offset with respect to intermediate recessed portion 19 by a substantially planar step portion 20.

Outer recessed portion 21 and intermediate recessed portion 19 are provided adjacent their longitudinal ends with vertically-extending relief portions 22 having a diagonally extending wall 23 and an arcuate wall 24. The wall 24 is shown provided with a bevelled portion 25 adjacent its outer end. An inwardly-extending slot 26 communicates with each arcuate wall 24 and is provided with a wedge-shaped entrance portion 27 formed in face 11 adjacent wall 24.

In operation, the insert 10 is equally effectivein protectively packaging TV tubes oriented either with their neck up or down. Outer recessed portion 21 and intermediate recessed portion 19 are contoured so as to coincide with the face edge and steel band respectively of Rimband type tubes. The outwardly-extending mounting lugs formed on the standard Rimband tubes are positioned within the inwardly-extending slots, with their insertion facilitated by the wedge-shaped entrance portion 27. When the packaging insert 10 is so positioned upon such Rimband tubes, the surface 13 faces rearwardly or in the direction of the neck or rear of the tube, while surface 12 faces forwardly in the direction of the crown or face of the tube.

When packaging the offset type Rimbaud tube, having the offset mounting lugs, the foam insert 10 is oriented in the same position in which it is used with the standard Rimbaud type of tube having the radially outwardly projecting mounting lugs. However, the offset portion of the mounting lugs on the offset Rimbaud type of tube are received within and accommodated by the vertically-extending relief portions 22, while the outwardly projecting mounting portion of such lugs is positioned adjacent and lies coincident with supporting surface 13. When in such position, the outer recessed portion surface 21 and the intermediate recessed portion 19 cooperate with the face edge'and steel band of the tube to provide a large surface area contact therewith.

When packaging Shelbond type tubes, the foam insert is reversed so that surface 12 is oriented to face backwardly of the tube while surface 13 faces forwardly thereof. The inner recessed surface portion 17 is contoured to lie along and complement the metal shell side of the tube so as to cushionably receive a large surface area of such tube. The mounting flanges formed integrally with the metal shell extend over and are coincident with supporting surface 12. r p

The foam plastic, which is preferably expanded polystyrene, provides suflicient bearing surface area to cushion the various tubes effectively and to resist rotation of the tube during shipment, so that the mounting lugs can neither contact each other nor tear the adjacent carton. In addition, reliable location and orientation of the foam supporting elements 10 is assured not only by the contoured surface portions, but also by locating the foam in positionrnent with respect to the tube lugs or flanges.

The double-curved surfaces of glass TV tubes are prone to point loading upon impact, when such tubes are packaged in flat sheet materials such as corrugated paperboard. With the utilization of our novel foam insert 10, however, the front face 11 is countered so as to be coincident with the tube side over a relatively large large area thereof which not onlyprovides an excellent surface cushioning effect, but also a positive positioning or holding effect. The energy-absorption characteristics of molded expandable polystyrene are such so as to distribute any impact loading throughout the large contacting contourned surface. Further, the density of the foam can also be controlled so as to provide desired energy-absorption characteristics.

In order to provide uniformity in packaging, the contoured step portion 18 between inner recessed portion 17 and intermediate recessed portion 19 is dimensioned so that the total distance from the center axis of the tube to the inner wall of the enclosing carton is identical for both the Rimbaud and Shelbond tube types. While it is apparent that when a pair of-the inserts 10 are positioned on opposite sides of a tube, the flat back surface 16 absorbs all impacts directed at such sides of the tubes and dissipates them along the extended contoured contacting surface 11,-the end surfaces 14 and also provide a protective measure. Surfaces 14 and 15 are formed tangent to the maximum width points of the sides of the tube which extend between such inserts, so as to not only provide a degree of protection along such sides intermediate the inserts, but also position the tube in a confining cell of a multipack to resist rotation which might otherwise lead to the lugs coming in contact with other tubes or carton walls.

To provide an added measure of protection, the height .of the foam part, or distance from supporting surface 12 to supporting surface 13, is identical to the parallel distance from the mounting lugs or flanges to the highest point or crown on the tube face, with respect to the offset Rimband and Shelbond tubes. In addition, the distance from the slots 26 to the surface 12 is identical to the parallel distance from the mounting lugs to the crown or highest point on the tube face of the standard Rimband tube. Accordingly, the tubes are not only held level when the mounting lugs are resting in their proper position on the foam parts, but also a planar protective surface is provided for the highest point of the face of the tube. If desired, the lug of the offset-type Rimbaud tube may be positioned within the slots 26 instead of lying coincident with the surface 13 as previously described.

Referring now to FIGURE 5, a plurality of TV tubes are shown positioned within a fragmental section of a multi-pack TV carton. The pack comprises an outer enclosing carton or container 30 having separator channels 31 provided with spacer blocks 32. A plurality of TV tubes are shown positioned withinthe container 30 in a face-down orientation. An offset Rimband type tube is shown at 33 positioned between a .pair of spacer blocks 10. The offset. mounting lugs of the tube 33 project upwardly Within the vertically-extending relief portions 22 and the mounting portions thereof overlie the support surface 13.

A standard Rimbaud tube having radially outwardlyextending mounting lugs is shown at 34 positioned between a pair of the insert members 10. The radially-extending mounting lugs of tubes 34 are shown positioned within the slots 26. It is noted that the back of the center insert member 10 for tube 34 abuts the back of the center-insert member 10 for tube 33, however, if desired, these members may be formed integrally as a unitary body.

A pair of Shelbond type tubes are shown at 35 each having an insert member 10 positioned at its outer end, and a unitary insert member 10' positioned therebetween. The insert member 10' is in effect a double insert member 10 formed integrally, back to back, such that the contoured surfaces thereof are mirror images of each other. As shown, the mounting flange portion of the Shelbond tubes 35 overlie the support surface 12 of'the insert member 10.

Although we have disclosed the preferred embodiments of our unique universal TV bulb packaging insert, it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.

We claim:

1. In the packaging of specialized television tubes having various types of implosion control bands and mounting lugs positioned thereon, a foamed plastic packaging element positioned on a pair of opposite sides of each such tube to cushionably receive and position the tube within a multi-pack container comprising, a substantially rectangular body member, said body member having at least one contoured face recessed to complement an edge portion of each of the various type tubes to be packaged and thereby provide a surface area contact with the packaged tube, a pair of support surfaces each communieating with a longitudinal edge of said contoured face, at least one of said support surfaces lying coincident with the crown of the face of each packaged tube while the mounting lugs of such tube are ope'ratively received and positioned by said body member, a pair of side surfaces extending between said support surfaces on said body member and lying tangent to the widest point on the edges of the packaged tubewhich extend outwardly from said contoured face.

2. In the packaging of specialized television tubes as defined in claim 1, a'pair of spaced-apart relief portions formed in said contoured face and communicating with one of said support surfaces receiving offset lugs on one type of the specialized tubes, and in inwardly extending slot communicating with each of said relief portions for positionably receiving mounting lugs on an additional type of the specialized tubes.

3. In the packaging of a plurality of specialized television tubes as defined in claim 1, said contoured face comprising an inner recessed portion extending longitudinally along said body member in communication with one of said support surfaces, an outer recessed portion extending longitudinally along said body member in communication with the other of said support surfaces, and an intermediate recessed portion between said inner and outer recessed portion and offset therefrom by stepped portions.

4. In the packaging of specialized television tubes as defined in claim 1, said body member having a pair of contoured faces on opposite sides of said member such that they are in effect mirror images of each other.

5. In combination with a multipack of any desired type of specialized television tubes which tubes may be provided with a variety of implosion control bands and mounting lugs, a universal packaging insert conforming to the various edge contours of such specialized tubes including the desired tube type packaged within such multipack carton which comprises, a body member of foamed plastic material having a substantially rectangular configuration positioned on opposite side edges of each packaged tube, at least one contoured face formed in said body member to complement the edge contours of the various specialized tubes including the desired type of packaged tubes, a pair of support surfaces each communicating with an opposite longitudinal edge of said contoured face, one of said support surfaces lying in a plane coincident with the crown of the face of the packaged tube, and a pair of side edges formed on said body member so as to lie tangent to the maximum width points of the edges of the packaged tube which extend between said body members.

6. The combination as defined in claim 5 wherein a pair of relieved portions are formed in said contoured face to receive offset mounting lug portions on the packaged tube.

7. The combination as defined in claim 5 wherein an inwardly-extending slot communicating with said contoured face extends inwardly of said body member for receiving mounting lug portions therein which extend outwardly from the packaged tube.

8. The combination as defined in claim 5 wherein said pair of support surfaces communicating with said contoured face operatively receive and position the mounting lugs of the packaged tubes and maintain them in spacedapart relationship from the enclosing carton and lugs of adjacent tubes.

9. The combination as defined in claim 5 wherein at least one of said body members is positioned adjacent an inner wall of the enclosing carton and has a substantially planar back wall opposite said contoured face positioned against an inner surface of the enclosing carton so as to cushionably position the packaged tube and its mounting lugs in cushioned spaced-apart relationship from such enclosing walls.

10. The combination as defined in claim 5 wherein at least one of said body members is positioned between a pair of packaged tubes and has a pair of contoured faces on opposite sides thereof each complementarily receiving an edge portion of a packaged tube to cushonably position such tubes in spaced-apart relationship with respect to each other.

11. The combination as defined in claim 5 wherein said foamed body member is made of expanded foamed polystyrene.

12. A universal packaging insert for cushionably positioning a variety of specialized television tubes of a given face size which comprises, a unitary foamed plastic body member, said body member being in the form of a rectangular block, a contoured front face formed in said block and extending between a pair of planar support surfaces, an inner recessed portion formed in said front face communicating with one of said support surfaces, an outer recessed portion communicating with the other support surface, an intermediate recessed portion positioned between said inner and outer recessed portions and offset with respect thereto by a pair of step portions, a relief portion for-med in both said outer and said intermediate recessed portions adjacent their opposite ends, and a slot communicating with each of said relief portions extending inwardly of said body member.

13. A foam plastic cushioning element for packaging a variety of specialized television tubes which comprises, a unitary body member of general rectangular configuration having a contoured front face, said front face being contoured to complement the contour of side edge portions of a variety of specialized TV tubes; said contoured face including an inner recessed portion extending along a longitudinal edge of such face, an intermediate recessed portion outwardly oifset from said inner recessed portion by a contoured step portion, and an outer recessed portion extending along an opposite longitudinal edge of such face and offset from said intermediate recessed portion by a substantially planar step portion; a pair of substantially planar support surfaces communicating with the opposite longitudinal edges of said contoured front face, a pair of relief portions extending transversely of the longitudinal extent of said outer and intermediate recessed portions and communicating with said opposite longitudinal edge, one of said relief portions being positioned adjacent each of the longitudinal ends of said outer recessed portion, and an inwardly-extending slot communicating with each of said relief portions and projecting inwardly of the body member.

References Cited UNITED STATES PATENTS 3,170,569 2/1965 Knapp et al. 206-46 THERON E. CONDON, Primary Examiner. MARTHA L. RICE, Examiner. 

12. A UNIVERSAL PACKAGING INSERT FOR CUSHIONABLY POSITIONING A VARIETY OF SPECIALIZED TELEVISION TUBES OF A GIVEN FACE SIZE WHICH COMPRISES, A UNITARY FOAMED PLASTIC BODY MEMBER, SAID BODY MEMBER BEING IN THE FORM OF A RECTANGULAR BLOCK, A CONTOURED FRONT FACE FORMED IN SAID BLOCK AND EXTENDING BETWEEN A PAIR OF PLANAR SUPPORT SURFACES, AN INNER RECESSED PORTION FORMED IN SAID FRONT FACE COMMUNICATING WITH ONE OF SAID SUPPORT SURFACES, AN OUTER RECESSED PORTION COMMUNICATING WITH THE OTHER SUPPORT SURFACE, AN INTERMEDIATE RECESSED PORTION POSITIONED BETWEEN SAID INNER AND OUTER RECESSED PORTIONS AND OFFSET WITH RESPECT THERETO BY A PAIR OF STEP PORTIONS, A 